APPLICATION

Application of batter and bread crumb on nuggets

The nuggets are coated with a shallow to thick layer of crispy dough and crumbs: the texture and appearance are intentionally rough. Combinations of operations and ingredients result in tasteful experiences when adequately mastered.

Updated Jan 01, 2021 - 10 min Read

BASE

Core products

The core product can be of various types: poultry, cheese, fish, vegetables, and fruits.

RECIPE

Ingredients

The batter is prepared with the following:

      • Wheat flour
      • Finer flour (maize, rice, tapioca) or native starch of the sort
      • Functional starch with expanding, binding, filming, and barrier properties
      • Active ingredients (proteins, hydrocolloids)
      • Fats
      • Leavening agents
      • Flavour and colour
      • Salt, spice
      • Water

The dry ingredients are first mixed, then the liquid is added. To avoid lumps, progressive liquid addition, and thorough mixing are required. The mix is prepared and stored at a low temperature and kept agitated. The choice of ingredients will determine the thickness and expansion.

In the case of prawn nuggets, the coating is very thick; in the case of French fries, the consistency is excellent, providing a barrier effect and retaining crispiness longer. After the liquid coating, the product is dusted and sprinkled with fine to coarse particles: breadcrumbs and Japanese crumbs.

RECIPE

Ingredients

The batter is prepared with the following:

      • Wheat flour
      • Finer flour (maize, rice, tapioca) or native starch of the sort
      • Functional starch with expanding, binding, filming, and barrier properties
      • Active ingredients (proteins, hydrocolloids)
      • Fats
      • Leavening agents
      • Flavour and colour
      • Salt, spice
      • Water

The dry ingredients are first mixed, then the liquid is added. To avoid lumps, progressive liquid addition, and thorough mixing are required. The mix is prepared and stored at a low temperature and kept agitated. The choice of ingredients will determine the thickness and expansion.

In the case of prawn nuggets, the coating is very thick; in the case of French fries, the consistency is excellent, providing a barrier effect and retaining crispiness longer. After the liquid coating, the product is dusted and sprinkled with fine to coarse particles: breadcrumbs and Japanese crumbs.

PROCESS

How does it work?

The process is a continuous operation.

Batter and crumb applications can be repeated two times to increase the thickness. After coating, the product needs to be stabilized:

  • Deep-frying in oil,
  • Cooling, during which the oil is absorbed.

Industrial products are cooled or frozen after coating. Frying is then done just before use.

Step 1.

Pre-dusting with fine flour (optional).

Step 2.

Batter coating.

Step 3.

Breadcrumb coating.

Step 4.

Deep-frying in oil.

Step 5.

Cooling during which the oil is absorbed.

PROCESS

Coating system

The operation occurs in a series of machines: Flour duster, optionally, Batter coater, and Breadcrumb coater.

The choice depends on the product type (size and shape) and the rheology of the coating ingredient mix (fluid/bridging, fine/coarse, fragile/resistant). The combination of machines depends on the recipe and number of operations.

PROCESS

Coating system

Selecting a system requires doing the test during which one observes the product motion during the application and its results, the behaviour of the ingredient mix, the recycling efficiency, the pollution, and potential hygiene hazards—picture courtesy of Barsso NV.

PRODUCT EVALUATION

How do you measure your success?

Key quality features

The evaluation of the nuggets is complex and carried out best by sensory evaluation.

Liquid and solid application plus frying and cooling conditions

Texture

The mouthfeel is characteristic. It associates softness and crispiness with limited oil pickup.

Aspect and flavor

Roughness and color appeal. The flavor of the coating enhances the cores.

Shelf-life

The nuggets must retain their desired features along the logistic chain until consumption.

Key quality parameters

Factors influencing the product end quality are multiple.

Liquid and solid application plus frying and cooling conditions

Core product

Type, shape, surface texture, moisture.

Ingredients

Flour and batter recipe, breadcrumb type.

Processing

Liquid and solid application plus frying and cooling conditions.